Rear door heat exchanger transition frame

ABSTRACT

A transition frame system integrates a liquid cooling door with associated computer equipment racks. Dissimilar dimensions of equipment racks and cooling doors are accommodated by a transition frame. The frame has a top, bottom, first side, and a second side; each providing a rack face opposing a door face. The frame may be one piece. The rack face includes a means for mating/sealing with the rack and the door face includes a means for mating/sealing with a cooling door that may include replacement hinges and latches. The transition frame can be included as part of the rack or the door. Cooling of equipment in the rack is maintained through airflow through the cooling door.

RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 61/106,691, filed Oct. 20, 2008; this application is herein incorporated in its entirety by reference.

FIELD OF THE INVENTION

The invention relates to a system and method to support cooling heat generating components, and more particularly, to a system and method for integrating a liquid cooling door with associated computer equipment racks.

BACKGROUND OF THE INVENTION

Liquid cooling of electronics cabinets to control heat rise is known. Increases in electronics density are accompanied by increases in heat production for a given volume of electronic equipment. This has reached the point where air conditioning systems are unable to cool computing facilities without supplemental liquid cooling.

Competition among computing providers such as server farms, communications vendors, and data storage centers has generated a need for reliable, scalable cooling solutions as they expand their facilities.

Rear door heat exchangers, such as that available from IBM and described in U.S. Pat. No. 7,385,810, are effective at dealing with data center hot-spots and facilitate the deployment of fully loaded racks. They offer space savings and flexibility for sites that have often exceeded their cooling capacity. They decrease the load on air conditioning and, with separate cooling circuits, can provide redundancy and added shut-down time should air conditioning fail. For example, temperatures can climb 2 degrees Centigrade per minute following air conditioning failure, resulting in server shut down and 100 degree Fahrenheit temperatures in less than 15 minutes. Rear door heat exchangers are also typically the most energy efficient data center cooling system.

Existing liquid cooling solutions however, require equipment racks custom designed for liquid heat exchangers. These are expensive and often exceed the needs and budget of start-ups and cost-sensitive operations. Currently, the upgrade options available are limited and operationally prohibitive, often requiring shutting down equipment and replacing the racks housing it. This rack replacement involving shutting down mission critical servers, removing the hardware, and reinstalling the equipment is a very expensive and labor intensive process.

No alternative may exist though, if expansion requires a new rack to accommodate a rear door heat exchanger. Upgrade paths are not normal in the industry. While standardized rack sizes exist, variations prevent direct interchangeability of components such as doors. Hinges and latches are an example of this variability. This lack of interchangeability requires an extensive initial investment for a more advanced rack than may be required at start-up if rear door heat exchangers are anticipated.

There is a need therefore, for an efficient, low labor, inexpensive, reliable and scalable apparatus and method for meeting the cooling needs of enterprises operating equipment generating increasingly greater heat loads.

SUMMARY OF THE INVENTION

A system and method for integrating a liquid cooling door with associated computer equipment racks is disclosed. Transition frame embodiments include replacements for rack hinges and latches, overcoming the lack of standards in this area. The solution enables the purchase of inexpensive air-cooled racks initially, when relatively few components are installed. Then, as rack capacity is reached by adding components resulting in peak heat loads, the existing rack can be retrofitted with a rear door heat exchanger.

Embodiments include a transition frame for a cooling system for an equipment rack comprising: a top; a bottom; a first side; and a second side; wherein each of the top, bottom, first side and second side has a rack face opposing a door face; wherein the rack face comprises a means for mating/sealing the rack; the door face comprises a means for mating/sealing a cooling door; wherein cooling of equipment in the rack is maintained through the door, and wherein dissimilar dimensions of the rack and the door are accommodated.

Another embodiment provides a transition frame for a cooling system for an equipment rack comprising an integrated component unitary body having a rack face opposing a door face; whereby mismatch of rack and door hinges and latches and dissimilar dimensions of the rack and door are accommodated and cooling of equipment in the rack is maintained through a cooling door adjacent to the transition frame door face.

Yet other embodiments include a transition frame for a cooling system for an equipment rack comprising a top connected to a first side and a second side, the sides connected to a bottom; wherein each of the top, bottom, first side and second side has a rack face opposing a door face; wherein the rack face is adjacent to the equipment rack and operationally connected with the rack; the door face is adjacent a cooling system door and operationally connected with the cooling door; wherein cooling of equipment in the rack is maintained through the door, and wherein dissimilar dimensions of the rack and the door are accommodated. For other embodiments, the cooling system door is a rear door heat exchanger, and the cooling system door is added without rack replacement and without equipment shut down. In one embodiment, the frame comprises a unitary body. In yet other embodiments, the frame is integrated with the equipment rack, and in others the frame is integrated with the cooling door. Further embodiments provide that at least one of the operational connection with the equipment rack and the operational connection with the cooling door comprises a replacement latch, and at least one of the operational connection with the equipment rack and the operational connection with the cooling door comprises an extendible gasket. In another embodiment, the gasket is conductive, whereby enclosure shielding is maintained. In yet a further embodiment, at least one of the operational connection with the equipment rack and the operational connection with the cooling door comprises at least one replacement hinge. In another, the at least one replacement hinge supports opening angles of up to 270 degrees. For some embodiments, at least one of the operational connection with the rack and the operational connection with the cooling door comprises threaded fittings-tapped in the transition frame, and at least one of the operational connection with the rack and the operational connection with the cooling door comprises slots. For another, the frame maintains operation of cooling hoses of the rear door heat exchanger.

Other embodiments provide a method of adapting a cooling door to a rack comprising the steps of providing a transition frame for a cooling system for an equipment rack comprising a top connected to a first side and a second side, the sides connected to a bottom; wherein each of the top, bottom, first side and second side has a rack face opposing a door face; wherein the rack face is adjacent the equipment rack and comprises a means for mating with the rack; the door face is adjacent a cooling system door and comprises a means for mating with the cooling door; wherein cooling of equipment in the rack is maintained through the door, and wherein dissimilar dimensions of the rack and the door are accommodated; and installing the transition frame on at least one of the rack and the door. For other embodiments, airflow impedance is maintained. In yet other embodiments, the frame comprises a unitary body, and the frame is integrated with the cooling door. Other embodiments provide that the frame is compliant with European Union directives on restriction of use of certain hazardous substances in electrical and electronic equipment.

Further embodiments include a transition frame for a cooling system for an equipment rack comprising a top connected to a first side and a second side, the sides connected to a bottom; wherein each of the top, bottom, first side and second side has a rack face opposing a door face; wherein the rack face is adjacent the equipment rack and comprises a means for mating with the rack; the door face is adjacent a cooling system door and comprises a means for mating with the cooling door; wherein cooling of equipment in the rack is maintained through the door, and wherein dissimilar dimensions of the rack and the door are accommodated.

The features and advantages described herein are not all-inclusive and, in particular, many additional features and advantages will be apparent to one of ordinary skill in the art in view of the drawings, specification, and claims. Moreover, it should be noted that the language used in the specification has been principally selected for readability and instructional purposes, and not to limit the scope of the inventive subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts simplified perspective diagrams of multi-component frame 1A, and integrated component frame 1B, configured in accordance with embodiments.

FIG. 2 is a simplified perspective diagram of transition frame alignment with a rack and cooling door configured in accordance with an embodiment.

FIG. 3 is a diagram of components comprising a first transition frame embodiment configured in accordance with an embodiment of the invention.

FIG. 4 is a diagram of components comprising a second transition frame embodiment configured in accordance with an embodiment of the invention.

FIG. 5 is a diagram of components comprising a third transition frame embodiment configured in accordance with an embodiment of the invention.

FIG. 6 is a diagram of components comprising a fourth transition frame embodiment configured in accordance with an embodiment of the invention.

FIG. 7 is a diagram of components comprising a fifth transition frame embodiment configured in accordance with an embodiment of the invention.

FIG. 8 is a diagram of components comprising a sixth transition frame embodiment configured in accordance with an embodiment of the invention.

FIG. 9 is a simplified diagram of transition frame first and second hinge embodiments configured in accordance with an embodiment of the invention.

FIG. 10 is a simplified diagram of a transition frame third hinge embodiment configured in accordance with an embodiment of the invention.

FIG. 11 is a simplified perspective diagram of transition frame latch interfaces configured in accordance with embodiments.

FIG. 12 is a simplified a perspective diagram of a transition frame integrated with a rack configured in accordance with an embodiment.

FIG. 13 is a simplified a perspective diagram of a transition frame integrated with a door configured in accordance with an embodiment.

DETAILED DESCRIPTION

The invention is susceptible of many embodiments. What follows is illustrative, but not exhaustive of the scope of the invention.

In the description, relative terms such as “horizontal,” “vertical,” “up,” “down,” “top” and “bottom” as well as derivatives should be construed to refer to the orientation as then described or as shown in the drawing figure under discussion. These relative terms are for convenience of description and normally are not intended to require a particular orientation. Terms including “inwardly” versus “outwardly,” “front” versus “back” and the like are to be interpreted relative to one another or relative to an axis as appropriate. Terms concerning attachments, coupling and the like, such as “connected” and “interconnected,” refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. The term “operatively connected” refers to such an attachment, coupling or connection that allows the pertinent structures to operate as intended by virtue of that relationship.

The term “electronics cabinet” is used interchangeably with “equipment rack” or “rack” in this application. It refers to a container for heat generating equipment. It may be any housing for containing components of an electronics system or computer system. Components may be standalone computers, power supplies, memory storage devices or communication interfaces, for example. The term heat exchanger is used to define any heat exchange mechanism through which coolant can circulate. It may include one or more discrete heat exchange devices coupled in series or in parallel.

Embodiments of the present invention provide a low-cost addition of liquid cooling to equipment racks, an installation requiring no down time, and an easy upgrade path maintaining investment in racks.

Elements of embodiments include a rack mating interface that is easy to connect and provides thermal benefits such as control of thermal expansion. Door mating interface embodiments provide easy connection, can conduct rack heat to door exchanger, and control thermal expansion.

Heat exchanger door hose configurations are accommodated by the transition frame rails and air flow control, including air flow impedance, is maintained.

Embodiments provide size adaptability to variations in rack height and or width. For example, various embodiments can support widths from approximately 25 to 35 inches and heights from approximately 76 to 83 inches. Transition frame hinge embodiments support locking, can hold the door open, and provide auto-opening. Hinge embodiments support opening angles of up to 270 degrees.

Sealing methods enable easy installation, are ultra-reliable, and maintain thermal control. In embodiments, conductive gaskets support electromagnetic interference (EMI) protection while maintaining the plenum function of the door housing to direct air through the heat exchanger. Gasket examples include Holland Shielding Systems BV Conductive Rubber 5750. In other embodiments, foam gaskets are used. Latch mechanism embodiments provide: an even gap, compression of the sealing gasket, ensure EMI control, airflow performance, and maintain environmental integrity of the enclosure. Embodiments provide narrow gaps between movable components of approximately ⅛ inch or less when closed.

Connections include, by nonlimiting example, bolts, screws, slide fittings, clamps, grommets, adhesive, interlocking fingers, mating channel, and surrounding gasket. In embodiments, screws affix to threaded fittings-tapped in the transition frame. No special modification is necessary to use transition frames. Transition frame embodiments provide for mismatches between rack and door hinges by supplying compatible replacement components. Embodiments are compliant with European Union directives on the restriction of the use of certain hazardous substances in electrical and electronic equipment. In particular, Directive 2002/95/EC on the Restriction of the Use of certain Hazardous Substances in Electrical and Electronic Equipment (ROHS) as of Jun. 15, 2009, providing that products not contain lead, cadmium, mercury, hexavalent chromium, polybrominated biphenyls (PBB) or polybrominated diphenyl ethers (PBDE) (Article 4(1)). This controls risk during fabrication and reduces personnel and disposal hazards while expanding markets.

FIG. 1 presents simplified perspective diagrams 100 of embodiments of multi-component 1A, and integrated unitary component 1B, transition frames. In FIG. 1A, top 105, bottom 110, first side 115, and second side 120 are configured to form a frame having rack face 125 and door face 130. Alternatively, the frame can be comprised of a single, integrated unitary, piece 135 as in FIG. 1B having rack face 140 and door face 145.

FIG. 2 is a simplified perspective diagram 200 of transition frame 205 alignment with rack 210 and cooling door 215. Embodiments of transition frame 205 direct airflow from the rack 210 through to heat exchanger door 215. The frame is depicted with hinges 220 and 225 and latch 230. The frame mates and seals rack and door peripheries. It provides hinge mounts for the heat exchanger door and supports coolant hoses without interference. Frame rail configurations can provide adjustment to fit multiple racks with multiple doors.

FIG. 3 is a diagram of components comprising a first transition frame embodiment 300 depicting vertical side 305 and cross section A-A 310 of vertical side 305. Second view 315 of vertical side depicts view B-B of section 310. Perspective view of horizontal side 320 is also shown in orthogonal view C-C 325.

FIG. 4 is a diagram of components comprising a second transition frame embodiment 400 depicting vertical side 405 and cross section A-A 410 of vertical side 405. Second view 415 of vertical side depicts view B-B of section 410. Perspective view of horizontal side 420 is also shown in orthogonal view C-C 425.

FIG. 5 is a diagram of components comprising a third transition frame embodiment 500 depicting vertical side 505 and cross section A-A 510 of vertical side 505. Second view 515 of vertical side depicts view B-B of section 510. Perspective view of horizontal side 520 is also shown in orthogonal view C-C 525.

FIG. 6 is a diagram of components comprising a fourth transition frame embodiment 600 depicting vertical side 605 and cross section A-A 610 of vertical side 605. Second view 615 of vertical side depicts view B-B of section 610. Perspective view of horizontal side 620 is also shown in orthogonal plan view C-C 625. Perspective view of horizontal side 630 is also shown in orthogonal view D-D 635.

FIG. 7 is a diagram of components comprising a fifth transition frame embodiment 700 depicting vertical side 705 and cross section A-A 710 of vertical side 705. Second view 715 of vertical side depicts view B-B of section 710. Perspective view of horizontal side 720 is also shown in orthogonal plan view C-C 725. Perspective view of horizontal side 730 is also shown in orthogonal view D-D 735.

FIG. 8 is a diagram of components comprising a sixth transition frame embodiment 800 depicting vertical side 805 and cross section A-A 810 of vertical side 805. Second view 815 of vertical side depicts view B-B of section 810. Perspective view of horizontal side 820 is also shown in orthogonal view C-C 825.

FIG. 9 is a simplified diagram of transition frame hinge interface embodiments 900. A first transition frame hinge interface embodiment is identified in 9A. First hinge component is shown in perspective 905, and orthogonal view 910. Note that hinge pin length is varied in embodiments with the top or bottom hinge's pin being longer to facilitate attachment alignment. A second transition frame hinge interface embodiment is identified in 9B. Second hinge component is shown in perspective 915, and orthogonal view 920. Note again that hinge pin length is varied in embodiments with the top or bottom hinge's pin being longer to facilitate attachment alignment. Transition frame embodiments provide for mismatches between rack and door hinges by supplying compatible replacement components.

FIG. 10 is a simplified perspective diagram of a third transition frame hinge interface embodiment 1000. Third hinge component is shown in perspective 1005, and orthogonal view 1010. Exploded view 1015 depicts individual components comprising hinge embodiments. Embodiments support opening angles of up to 270 degrees.

FIG. 11 is a simplified perspective diagram of transition frame latch interface embodiments 1100. First 1105, and second, 1110, latch components are shown in perspective. As with the transition frame hinge interface, transition frame embodiments provide for mismatches between rack and door latches by supplying compatible replacement components.

FIG. 12 is a simplified perspective diagram of an embodiment of a transition frame integrated with a rack 1200 showing equipment rack 1205 with transition frame 1210 integrated with its face to accommodate cooling door (not shown). This provides initially for a rack unit to accommodate a cooling door.

FIG. 13 is a simplified perspective diagram of an embodiment of a transition frame integrated with a door 1300 showing cooling door 1305 with transition frame 1310 integrated with its face to accommodate equipment rack (not shown). This provides initially for a door unit to accommodate an equipment rack.

Other and various embodiments will be readily apparent to those skilled in the art, from this description, figures, and the claims that follow.

The foregoing description of the embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of this disclosure. It is intended that the scope of the invention be limited not by this detailed description, but rather by the claims appended hereto. 

1. A transition frame for a cooling system for an equipment rack comprising: a top connected to a first side and a second side, said sides connected to a bottom; wherein each of said top, said bottom, said first side and said second side has a rack face opposing a door face; wherein said rack face is adjacent said equipment rack and operationally connected with said rack; said door face is adjacent a cooling system door and operationally connected with said cooling door; wherein cooling of equipment in said rack is maintained through said door, and wherein dissimilar dimensions of said rack and said door are accommodated.
 2. The transition frame of claim 1 wherein said cooling system door is a rear door heat exchanger.
 3. The transition frame of claim 1 wherein said cooling system door is added without rack replacement and without equipment shut down.
 4. The transition frame of claim 1 wherein said frame comprises a unitary body.
 5. The transition frame of claim 1 wherein said frame is integrated with said equipment rack.
 6. The transition frame of claim 1 wherein said frame is integrated with said cooling door.
 7. The transition frame of claim 1 wherein at least one of said operational connection with said equipment rack and said operational connection with said cooling door comprises a replacement latch.
 8. The transition frame of claim 1 wherein at least one of said operational connection with said equipment rack and said operational connection with said cooling door comprises an extendible gasket.
 9. The transition frame of claim 8 wherein said gasket is conductive, whereby enclosure shielding is maintained.
 10. The transition frame of claim 1 wherein at least one of said operational connection with said equipment rack and said operational connection with said cooling door comprises at least one replacement hinge.
 11. The transition frame of claim 10 wherein said at least one replacement hinge supports opening angles of up to 270 degrees.
 12. The transition frame of claim 1 wherein at least one of said operational connection with said rack and said operational connection with said cooling door comprises threaded fittings-tapped in said transition frame.
 13. The transition frame of claim 1 wherein at least one of said operational connection with said rack and said operational connection with said cooling door comprises slots.
 14. The transition frame of claim 2 wherein said frame maintains operation of cooling hoses of said rear door heat exchanger.
 15. A method of adapting a cooling door to a rack comprising the steps of: providing a transition frame for a cooling system for an equipment rack comprising: a top connected to a first side and a second side, said sides connected to a bottom; wherein each of said top, said bottom, said first side and said second side has a rack face opposing a door face; wherein said rack face is adjacent said equipment rack and comprises a means for mating with said rack; said door face is adjacent a cooling system door and comprises a means for mating with said cooling door; wherein cooling of equipment in said rack is maintained through said door, and wherein dissimilar dimensions of said rack and said door are accommodated; and installing said transition frame on at least one of said rack and said door.
 16. The method of claim 15 wherein airflow impedance is maintained.
 17. The method of claim 15 wherein said frame comprises a unitary body.
 18. The method of claim 15 wherein said frame is integrated with said cooling door.
 19. The transition frame of claim 1 wherein said frame is compliant with European Union directives on restriction of use of certain hazardous substances in electrical and electronic equipment.
 20. A transition frame for a cooling system for an equipment rack comprising: a top connected to a first side and a second side, said sides connected to a bottom; wherein each of said top, said bottom, said first side and said second side has a rack face opposing a door face; wherein said rack face is adjacent said equipment rack and comprises a means for mating with said rack; said door face is adjacent a cooling system door and comprises a means for mating with said cooling door; wherein cooling of equipment in said rack is maintained through said door, and wherein dissimilar dimensions of said rack and said door are accommodated. 